Building a Small Wind Turbine: Building the Flywheel

What You'll Need
Drill Bits (7/32 inch, 1/4 inch, 5/16 inch)
Jigsaw with a metal blade
Pipe Wrench
Flat Head Screwdriver
Crescent Wrench
Vise and/or Clamp
Wire Strippers
Tape Measure
Marker Pen
Compass + protractor
1/4 inch #20 Thread Tapping Set
8-inch PVC tubing for turbine blades
24" length of 8" PVC Pipe (if it is UV resistant, you will not need to paint it)
6-inch x 1/4 -inch x 20-inch Bolts
9-inch x 1/4 -inch washers
3 sheets A4 paper and tape

This article is just one part of a series of guides that will help you build a small wind turbine on your own. In this section, you will learn how to build the flywheel for your small wind turbine. The flywheel is basically your blades and the hub that connects the blades together, rotating to create the energy from the wind. So, when you're ready, prepare the tools and materials needed for the small wind turbine, especially for building the flywheel. After that, the steps to build the blades will follow. Again, please note that this guide is just for preparing the blades that make up the small wind turbine's flywheel.

Step 1 – Mark Pipes and Square Tubing

Lay your PVC pipe and square tubing on a flat surface. Make sure that the 24-inch length of the pipe is placed next to the square tubing. You may also use a straight edge instead of a square tube. Now, push them side by side, marking the line where they touch. This first mark will be called your Line A. Make a mark near each end of your Line A with 23 inches apart.

Step 2 – Prepare the Paper Form

Attach the A4 sheets of paper together by taping it. Make sure to make a long and straight blade lines piece or paper form. Now, wrap it around the section of your pipe where you made your marks. Make sure that your short side will lay straight along your Line A. At the same time, the paper should be straight when it overlaps itself. Now, mark a line along the edge of the paper on each end. One line will be called Line B and the other Line C.

Step 3 – Mark Intersections

Now starting from where Line A intersects with Line B, go left around Line B and make sure to mark every 145 mm. If you do this correctly, your last section will leave you with more or less 115 mm. Do the same with the Line C, but this time go towards the right and start marking every 145 mm. Make sure you mark each line with a straight edge.

Step 4 – Cut Along the Lines

Using a jigsaw, cut through the lines so that you will have 4 strips of 145 mm and one strip of 115 mm. Take each strip and position them so that the inside of the pipe is faced downward. Now start marking at each end of the strip 115 mm from the left. On the other end, measure 30 mm from the left edge and mark it as well. Now, cut the lines using your jigsaw.

Now, you have created shaped blades for your small wind turbine. You may sand it to achieve a better look. It will also help make your blades quieter later on when you have assembled your small wind turbine.